Transfer case gear tooth ache...!

dorcom · 03-21-08, 07:30 PM

Welll, started to replace my speedometer gear since the nylon gear broke.
But then I found some metal parts!
Took the lid off, oh boy! A tooth ache here! see pics)
The third pic shows the remains of the nylon gear plus the metal pieces found.
What could have caused that?
I did noticed a slight hiss in 4th & 5th gear for some time.
more tomorrow.

D

dorcom · 03-21-08, 07:33 PM

gear tooth ache close up.
Notice the roughed up gear teeth surface!
What to do? Ignore? Keep on drivin'?

dorcom · 03-22-08, 11:43 PM

UPDATE

Why you should take the flange off when the nylon gear broke:
(look at the seal!)

MutleyFJ62 · 03-23-08, 04:04 AM

Complete tear down, flush and new stuff where needed. Do it once, do it properly.

NCCruiser302 · 03-23-08, 06:43 PM

Agreed, I bought my cruiser with 240,000 miles and no up-keep by the previous owner, my t-case was completely filled with mud. Gave it a good flush(it took more than 1) and was good to go

lehiguy · 03-24-08, 10:18 AM

What I'm seeing in your pictures is typical of a gear alignment problem, which is almost always cuased by a bearing that crapped it pants. You found the problem, make sure you find the cause or it will happen again. My first guess would be the idler bearing, that seems to be the first thing that goes. Second would be the output shaft bearings. I would be surprised if it was the bearings on the input shaft, but you never know. Good luck! This might be a good time to consider a set of Trail Tamer gears.

dorcom · 03-28-08, 09:53 AM

Here's the "damage":
With a mini file I filed out all the kinks in the speedo gear and polished it with wire brush attachment. The rear output shaft bearing came close to total damage! Look at the banged up roller cage!

dorcom · 03-28-08, 09:56 AM

Ouch! Maybe some one shifted the transfercase while driving!
All assembled ready to go.
car runs fine again!

03-21-08, 07:30 PM	#1
dorcom IH8MUD Rookie Join Date: Dec 2005 Posts: 59	Transfer case gear tooth ache...! Welll, started to replace my speedometer gear since the nylon gear broke. But then I found some metal parts! Took the lid off, oh boy! A tooth ache here! see pics) The third pic shows the remains of the nylon gear plus the metal pieces found. What could have caused that? I did noticed a slight hiss in 4th & 5th gear for some time. more tomorrow. D Attached Images __________________ '86 FJ60 bought Dec. '05 for $ 1,500 with 271,000 miles... driving on for 2 1/2 years toward 285,000 miles [almost] worry free!!! Last edited by dorcom; 03-21-08 at 08:07 PM.

03-21-08, 07:33 PM	#2
dorcom IH8MUD Rookie Join Date: Dec 2005 Posts: 59	gear tooth ache close up gear tooth ache close up. Notice the roughed up gear teeth surface! What to do? Ignore? Keep on drivin'? Attached Images __________________ '86 FJ60 bought Dec. '05 for $ 1,500 with 271,000 miles... driving on for 2 1/2 years toward 285,000 miles [almost] worry free!!! Last edited by dorcom; 03-21-08 at 08:05 PM.

03-22-08, 11:43 PM	#3
dorcom IH8MUD Rookie Join Date: Dec 2005 Posts: 59	UPDATE Why you should take the flange off when the nylon gear broke: (look at the seal!) Attached Images __________________ '86 FJ60 bought Dec. '05 for $ 1,500 with 271,000 miles... driving on for 2 1/2 years toward 285,000 miles [almost] worry free!!! Last edited by dorcom; 03-28-08 at 09:47 AM.

03-23-08, 04:04 AM	#4
MutleyFJ62 IH8MUD Junior Join Date: May 2005 Location: Gold Coast, QLD, Australia Posts: 164	Complete tear down, flush and new stuff where needed. Do it once, do it properly. __________________ Now an employee of your friendly TJM accessory shop www.tjm.com.au

03-24-08, 10:18 AM	#6
lehiguy IH8MUD Regular Join Date: Mar 2008 Posts: 397	Gear breakage What I'm seeing in your pictures is typical of a gear alignment problem, which is almost always cuased by a bearing that crapped it pants. You found the problem, make sure you find the cause or it will happen again. My first guess would be the idler bearing, that seems to be the first thing that goes. Second would be the output shaft bearings. I would be surprised if it was the bearings on the input shaft, but you never know. Good luck! This might be a good time to consider a set of Trail Tamer gears. __________________ 1985 FJ60, 300HP SBC, NV4500, NP241, 14-bolt semi floater, 4.56 gears, four wheel disk brakes, 35" BFGs, 350,000 happy miles and still going.

03-23-08, 06:43 PM	#5
NCCruiser302 IH8MUD Rookie Join Date: May 2006 Location: Asheville, NC Posts: 39	Agreed, I bought my cruiser with 240,000 miles and no up-keep by the previous owner, my t-case was completely filled with mud. Gave it a good flush(it took more than 1) and was good to go

03-28-08, 09:53 AM	#7
dorcom IH8MUD Rookie Join Date: Dec 2005 Posts: 59	transfer case tooth ache Here's the "damage": With a mini file I filed out all the kinks in the speedo gear and polished it with wire brush attachment. The rear output shaft bearing came close to total damage! Look at the banged up roller cage! Attached Images __________________ '86 FJ60 bought Dec. '05 for $ 1,500 with 271,000 miles... driving on for 2 1/2 years toward 285,000 miles [almost] worry free!!!

03-28-08, 09:56 AM	#8
dorcom IH8MUD Rookie Join Date: Dec 2005 Posts: 59	Transfer case tooth ache Ouch! Maybe some one shifted the transfercase while driving! All assembled ready to go. car runs fine again! Attached Images __________________ '86 FJ60 bought Dec. '05 for $ 1,500 with 271,000 miles... driving on for 2 1/2 years toward 285,000 miles [almost] worry free!!!

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